Composition and method for installing a simulated natural surface

ABSTRACT

A method of producing a simulated natural surface, such as stone, tile, brick or wood planking uses all environmentally friendly components. First, a water-based polymer liquid is applied to the existing surface using a roller. Next, a self-leveling mixture of water, polymer, cement and sand is applied with minimal trowelling in order to spread the mixture evenly over the surface. The applied mixture settles in a self-leveling manner. When partially cured, a desired grout pattern is scored in the applied cementous mixture to create the desired pattern (i.e., brick, stone, tile, wood planking). Next, the entire surface is painted with a prime coat of an acrylic paint including the scored grout lines. Once the prime coat dries, shading containing an organic oxide pigment is applied using a sponge. Alternatively, a marble appearance is created by applying drops of ink or other liquid pigment to the self-leveling cementous layer while still wet, which allows the drops to bleed and create a natural marble veining appearance. Lastly, a water-based glaze is applied over the entire surface as a sealer.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to compositions and methods for producing a simulated natural surface and, more particularly, to a composition containing environmentally friendly components and a method of installation requiring minimal labor to create a highly aesthetic surface that simulates natural stone, brick, tile or wood planking.

2. Discussion of the Related Art

Building materials, such as natural stone, tile, brick and wood planking have become considerably expensive in the present construction and home improvement market. Moreover, installation of such materials for flooring, walls and outdoor surfaces is labor intensive and requires skilled labor, thus adding to the total cost of a project.

Producing a simulated natural surface is a cost effective alternative, particularly when upgrading old surfaces, such as unsightly concrete decks, driveways and indoor floors. In the past, others have proposed methods of producing simulated brick or tile surfaces. Examples of such methods are disclosed in U.S. Pat. Nos. 1,815,608; 2,595,142; 2,602,232; 2,660,217; 2,748,443; 2,819,495; 3,177,279; 3,882,218; 4,080,767; and 4,271,111. However, these prior art methods failed to provide a commercially feasible process for making a simulated brick or tile that had durability and produced the appearance of the genuine natural product. My prior inventions disclosed in U.S. Pat. Nos. 4,349,588 and 4,868,018 provided methods of producing simulated brick, tile or marble surfaces using a mixture of cement, a pigment, a water-based adhesive and/or an epoxy resin. My previous methods, as disclosed in these patents, were effective to provide a simulated brick, stone, or marble surface having the appearance of the genuine natural product. However, my prior methods were somewhat labor intensive, requiring the installer to trowel the applied mixture while down on the knees, in order to smooth the entire surface. A further limitation of my prior inventions involves the use of polyvinyl acetate latex, epoxy resin, epoxy hardener and other components that are not environmentally friendly.

Accordingly, there remains a need for a cost effective and environmentally friendly composition and method for producing a simulated surface, such as stone, tile, brick or wood planking, requiring minimal labor and skill using water-based components that avoid obnoxious odors, damage to the ozone layer and other negative environmental impact.

Objects and Advantages of the Invention

Considering the foregoing, it is a primary object of the present invention to provide a composition and method for producing a simulated natural surface using environmentally friendly components, with minimal labor, thereby improving on the prior art methods and compositions.

It is a further object of the present invention to provide a composition for creating a simulated natural surface, and wherein, the composition includes self-leveling characteristic, thereby minimizing labor by reducing the amount of trowelling required to spread the composition evenly over a surface.

It is still a further object of the present invention to provide a composition and method for installing a simulated natural surface that is waterproof, fireproof, lightweight and termite proof.

It is still a further object of the present invention to provide a composition and method for installing a simulated natural surface in less time, with less labor and at a lower cost than comparable compositions and methods in the prior art.

These and other objects and advantages of the present invention are more readily apparent with reference to the detailed description and accompanying drawings.

SUMMARY OF THE INVENTION

The composition and the method of the present invention are directed to producing a simulated surface, such as stone, tile, brick or wood planking, using all environmentally friendly components. First, a water-based polymer liquid is applied to the existing surface using a roller. Next, a self-leveling mixture of water, polymer, cement and sand is applied with minimal trowelling in order to spread the mixture evenly over the surface. The applied mixture settles in a self-leveling manner. When partially cured, a desired grout pattern is scored in the applied cementous mixture to create the desired pattern (i.e., brick, stone, tile, wood planking). Next, the entire surface is painted with a prime coat of an acrylic paint, including the grout lines. Next, shading containing an organic oxide pigment is applied using a sponge. Optionally, an ink pigment can be applied to the surface of the self-leveling cementous mixture when it is still wet by applying drops of ink at spaced locations throughout the wet surface to provide a natural marble appearance. When the ink drops settle into the wet cementous mixture, the ink bleeds and creates a natural marble veining appearance that simulates a seamless marble surface. Ideally, this natural marble appearance should be created without the use of any grout lines, thereby providing the seamless appearance. However, grout lines can be scored after the marbleizing step if desired. Lastly, a water-based glaze is applied over the entire surface.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature of the present invention, reference should me made to the accompanying detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is an isolated perspective view showing an existing surface over which the composition of the present invention is applied in accordance with the method to create a simulated natural surface;

FIGS. 2, 4A, 5A and 6 illustrate a sequence of application of the composition of the present invention to the existing surface of FIG. 1 to create a simulated natural stone surface with grout lines according to the method of the present invention.

FIGS. 2, 4B and 6 illustrate a sequence of application of the composition to the existing surface of FIG. 1 to create a seamless marble simulated surface according to the method of the present invention; and

FIG. 7 is a block diagram indicated a series of steps to perform the method of the present invention for creating either the simulated natural stone surface of FIG. 6 or the seamless marble surface of FIG. 4B.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A first mixture for use in producing a simulated surface is prepared by mixing together a 40% polymer liquid with 60% water. In a preferred embodiment, the polymer liquid is a masonry coating polymer. The first mixture, providing a boding agent, is applied to an existing surface using a roller. Next, a second mixture is prepared by mixing together 80% water with 20% polymer having a self-leveling characteristic. In a preferred embodiment, the polymer is a masonry coating polymer. A cementous mixture comprising 50% Portland cement and 50% sand is combined with the second mixture and fully mixed to provide a self-leveling cementous mixture. The self-leveling cementous mixture is applied to the surface, using a trowel in a minimal action to evenly spread the self-leveling cementous mixture over the surface. When the mixture is partially cured, a tool is used to score in the desired grout pattern by scraping away a portion of the cementous mixture. The created grout lines resemble those of a genuine installation of either brick, stone, tile or wood planking. Next, a prime coat of acrylic paint is applied over the entire surface, including the grout lines. Shading is then applied to the surface using an organic iron oxide 100% pigment powder mixed with 25% solid acrylic and 75% water. The desired coloring and shading is applied with a camel back sponge without touching the grout lines. Alternatively, to create a natural marble appearance, ink drops are applied at spaced, random locations throughout the surface, prior to fully curing, to allow the ink drops to settle and bleed into the composition, thereby creating a natural marble veining appearance. When performing this step, it is preferable to skip the step of creating grout lines, so that the natural marble appearance simulates a seamless marble surface. Finally, an environmentally friendly high solid water-based glaze is applied as a sealer. The sealer is preferably applied using a roller applicator. 

1. A method of producing a simulated natural surface over an existing surface comprising: providing a bonding agent comprising 40% polymer liquid and 60% water; applying the bonding agent to the existing surface; providing a second mixture comprising 20% polymer and 80% water; providing a cementous mixture comprising 50% Portland cement and 50% sand; combining and thoroughly mixing the second mixture and the cementous mixture to produce a self-leveling cementous mixture; applying a layer of the self-leveling cementous mixture over the bonding agent previously applied to the existing surface; applying at least one pigment of a desired color to the previously applied self-leveling cementous mixture prior to curing of the self-leveling cementous mixture; allowing the self-leveling cementous mixture to fully cure; and applying a water-based sealer over the self-leveling cementous mixture.
 2. The method as recited in claim 1 comprising the further step of: scoring the applied layer of the self-leveling cementous mixture, prior to curing and prior to said step of applying at least one pigment, to create desired grout line patterns.
 3. The method as recited in claim 2 wherein said step of applying said at least one pigment includes avoiding application of said at least one pigment to said scored grout lines.
 4. The method as recited in claim 1 wherein said at least one pigment is an organic iron oxide.
 5. The method as recited in claim 4 wherein said step of applying at least one pigment includes: applying said at least one pigment using a sponge without touching the scored grout lines.
 6. The method as recited in claim 1 wherein said at least one pigment is ink.
 7. The method as recited in claim 6 wherein said step of applying at least one pigment includes: applying drops of the ink at spaced, random locations throughout the layer of self-leveling cementous mixture while the self-leveling mixture is still wet and allowing the drops to bleed into the layer to create a marble veining appearance.
 8. The method as recited in claim 1 wherein said polymer of said bonding agent is a masonry coating polymer.
 9. The method as recited in claim 1 wherein said polymer of said second mixture is a masonry coating polymer.
 10. The method as recited in claim 2 further comprising the step of: painting the entire cured surface of the self-leveling cementous mixture, including the scored grout line patterns, with a prime coat of acrylic paint. 